REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Rio (2000 release)

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Kia
	Rio
		Instructions
		Engines A3E, A5D
		Greasing system
		Cooling
		Fuel system
		Ignition system
		Coupling
		Transmission
		Axes and power shafts
		Suspension
		Wheels and tires
		Steering
		Brakes
		Body
		The air conditioning system
		Electrical equipment
			Technical data
			Electrical circuits
			Generator
				Check generator
				Alternator drive belt
				Removal, repair and generator installation
			Accumulator battery
			Starter
			Check while cranking the engine is not warmed-up engine
			Check the electrical circuit of the traction relay
			Check of the traction relay
			Check of brushes and brush holder
			Checking the stator coils
			Check rotor
			Removing and installing starter
			Repair of starter
			Multifunction switch
			Sound signal
			Fuse and relay, established in car salon
			Check the door lock switch activator
			Check of the switch of adjustment of position of the door mirror
			Check activator position outside rearview mirror
			Checking the engine window
			Check the rear window defogger
			Repair of a current-carrying strip of a heater
			Windshield Wiper Motor
			Washers
			Adjusting headlights
			Adjustment of light fog lights
			Airbags (SRS)
			Warning Labels
			Airbag and a spiral wire
			Check airbags
			Checking the spiral wire (spring)
			The front passenger airbag
			Electrical circuits

Removal, repair and generator installation

Withdrawal

PERFORMANCE ORDER

1. Disconnect the negative battery terminal.
2. Remove the cap from the terminal to the generator.
3. Remove the nut fastening wires to the terminals of the generator.
4. Remove the wire from the terminal to the generator.
	5. Disconnect the generator.
	6. Loosen the pivot bolt B for the generator and the mounting bolts A tensioning mechanism.
7. Turn the adjusting bolt C, loosen the tension of the alternator drive belt.
8. Remove the drive belt from the alternator pulley.
9. Remove the bolt tensioner.
10. Remove the hinge bolt of the generator.
11. Loosen the bolt of the adjustment bracket and rotate the bracket.
12. Remove the generator from the engine.

Dismantling

A warning

Replace the jaws soft protectors to avoid damage to the generator components.

PERFORMANCE ORDER

	1. Secure the generator in a vice and remove the four screws that secure the back cover of the generator.
	2. Palniki, 200W heat back cover and remove it from the generator.
A warning If the back cover is not heated, it is very difficult to remove due to the very tight fit.
	3. The flat-blade screwdriver to remove the front cover of the generator with the rotor.
A warning Be careful not to lose the retaining spring, which is located at the rear bearing. Replace the jaws soft protectors to avoid damage to the generator components.
	4. Fix the rotor in a vice and unscrew the nut, then remove the pulley rotor and the front cover.
5. If necessary, use a puller, remove the front bearing from the shaft of the generator.
	6. A stripper remove the rear bearing from the shaft of the generator.
7. Remove the nut at terminal B and remove the insulating sleeve.
	8. Remove the five screws and remove the rectifier and brush holder.
	9. Divide the back cover and the stator.
	10. Soldering iron Unsolder rectifier and wires, then remove the voltage regulator.
A warning Otpaivanie held no longer than 5 seconds, as otherwise it may be damaged by the voltage regulator.
	11. Replace brushes. Unsolder braided wire and remove the brush.

Check rotor

PERFORMANCE ORDER

	1. An ohmmeter measure resistance between contact rings. If the resistance is not correct, replace the rotor. Resistance: 3.5-4.5 ohms
	2. An ohmmeter check up conductivity between the contact ring and the anchor of the rotor. In the presence of conductivity replace the rotor.
3. If the surface of the contact ring has a roughness or traces of wear and tear, strip it with sandpaper.

Checking the stator

PERFORMANCE ORDER

1. An ohmmeter check up conductivity between the wires of the stator coils.
	2. In the absence of conductivity, replace the stator.
3. An ohmmeter check up conductivity between the stator coils.
	4. In the presence of conductivity, replace the stator.

Check rectifier unit

PERFORMANCE ORDER

	1. An ohmmeter check up conductivity between the terminals of each diode.
	2. If necessary, replace the rectifier.

Check bearings

PERFORMANCE ORDER

1. Check bearings for smooth rotation, no jamming and noise during rotation, and play.
	2. If there are any defects, replace the bearing.

Assembly

PERFORMANCE ORDER

	1. Set the brush and solder the braided wire so that the line of limiting deterioration brush acted on 2-3 mm from the brush holder.
	2. Solder the voltage regulator rectifier and stator windings.
A warning Solder wire for no more than 5 seconds, because otherwise it may be damaged by the voltage regulator.
3. Assemble the rear cover and the stator.
4. Replace the screws that secure the rectifier and brush holder. Torque: 2,0-5,4 N ??? m
	5. Install the grommets in the terminal B and fix their nuts.
	6. Install the rear bearing and secure with spring retainer.
A warning Check that the groove in the bearing housing is flush with the end of the bearing.
	7. Install the front bearing of the generator. To install the bearing is desirable to use a manual press mandrel, whose diameter corresponds to the diameter of the outer ring of the bearing.
8. Support the rotor in a vise, install the front cover and a pulley. Secure the pulley nut. Torque: 59-98 N ??? m
9. Replace the back cover of the generator and fasten with four screws. Torque: 2,9-6,4 N ??? m

Setting

PERFORMANCE ORDER

1. Place the generator on the engine.
2. Screw but do not tighten the hinge bolt of the generator.
3. Turn the bracket to its original position.
4. Install the tensioner on the bracket.
5. Screw but do not tighten the bolt tensioner.
6. Install the alternator drive belt on alternator pulley.
	7. Turn the adjusting bolt C, adjust the tension of the alternator drive belt. Deflection alternator drive belt New 5.5-7.0 mm Second hand 6.0-7.0 mm
	8. Tighten the bolt pad adjusting plate. Torque: 19-26 N ??? m
9. Tighten the pivot bolt and bolt bracket. Torque: 38-51 N ??? m
10. Connect the generator connectors L and S.
11. Connect a wire to the terminals of the generator.
12. Secure the nut at terminal B.
13. Close the terminal in the generator protective cap.
14. Install the air inlet and fix its collar.
15. Install the intake of fresh air.
16. Replace the front bolts intake of fresh air.
17. Connect the cable to the negative terminal of the battery.
A warning Make sure the battery cables are correctly connected. Do not use high-voltage devices, such as a megohmmeter to check for resistance. Remember that the battery voltage is always applied to the terminals of the alternator. Do not connect to "weight" contact L for the engine. Do not start the engine, while the contacts L and S are disconnected from the generator.